Method and apparatus for regulating pressure



Dec. 9, 1941.

METHOD AND APPARATUS FOR REGULATING PRESSURE Filed Jan. 19, 1939 2 Sheets-Sheet 1 ATTO R N EYS s. F. WADDELL 2,265,210

,without excessive or insufilcient pressure.

Patented Dec. 9, 1941 UNITED. STATE METHOD AND APPARATUS FOR REGULAT- ING PRESSURE Benson F. Waddell, Newark, N. .L, assignor to The Wilcolator Company, Newark, N. 3., a co!- poration of Delaware Application January 19, 1939, Serial 1%. 251,716

4 Claims.

This invention relates to the regulation of pressures and has particular reference to a novel method of regulating the pressure and flow of gas to a burner in accordance with the pressure in a separate, relatively minute stream of the gas which may supply a pilot for the burner. The new method is simple, reliable and economical and may be performed efliciently by a novel pressure regulator which forms part of the invention.

In the operation of gas burners having a pilot, the gas is commonly supplied to the burner and the pilot from a gas mainthrough an automatic pressure regulator. The regulator is necessarily quite large since its control valve must be capable of passing enough gas to operate both the pilot and the burner when the latter is turned on to full capacity. With a regulator of this size, it is difficult to provide a sufliciently sensitive control of the valve to operate the small pilot alone Accordingly, the pilot frequently burns too much gas and results in waste or, if the pressure becomes sure.

too low, is extinguished. Another method employed heretofore is to supply gas to the pilot through a needle valve independently of the burner control valve. Generally, the needle valve may be manipulated to obtain the required flow for efiicient operation of the pilot. However, a sudden decrease in the pressure at the supply main or a sudden increase in the demand of the burner may cut down the flow through the needle valve sufliciently to extinguish the pilot and thereby create a dangerous condition.

One feature of the present invention, therefore, resides in the provision of a novel method and apparatus for supplying gas to a heater, including a burner and a pilot. whereby the pressure at the pilot remains substantially constant at all times regardless of the operation of the burner or variations in the pressure at the supply main.

According to the new method, gas is bled from the supply main in a minute stream through a zone of intermediate pressure to a low pressure zone which communicateswith both the burner and the pilot. The flow between the zones of intermediate and low pressure is valved in accordance with pressure changes in the low pressure zone, so as to maintain a substantially constant pressure in the low pressure zone. The

the other side to the pressure in the intermediate zone. Also, the valving of the small stream between the intermediate and low'pressure zones may be conveniently efiected with a small auxiliary valve controlled by a diaphragm subjected on one side .to the pressure in the low pressure zone and on the opposite side to a constant pres- With this method, the supply of gas to both the burner and the pilot is controlled by the pressure in the low pressure zone of the small stream, so that regardless of pressure variations in the supply main or changes in the demand of the burner, the low pressure zone and the outlet gas are maintained at constant pressure. More particularly, when the pressure in the supply main decreases, the tendency for the pressure in the low pressure zone to decrease with it immediately causes the auxiliary valve for the small stream to open wider and permit more gas to flow from the intermediate zone into the low pressure zone, 'wherebythe pressure in the latter'is restored; Conversely, if the pressure in the main should increase, the tendency for the pressure in the low pressure zone to increase with it causes the auxiliary valve immediately "to shut down the flow of gas from the intermediate zone, whereby the pressure in the low pressure zone decreases to the desired amount.

When the demand of the burner increases, the

pressure in thelow pressure zone communicating with the burner tends to decrease and immediately causes the auxiliary valve to open wider and increase the how from the intermediate pressure zone. As a result, the pressure in the intermediate zone decreases and permits the large valve to open wider under the action of the pressure in the gas main, so as to meet the increased demand of the burner. On the other hand, if the demand of the burner should decrease the gas supplied to it builds up a pressure which is communicated to the low pressure zone of the small stream and causes the auxiliary valve to reduce the flow of gas from the intermediate zone to the low pressure zone. This, in turn, causes the pressure in the intermediate zone to build up and close down the large valve-against the pressure in the main, so that the flow through the large valve is now adjusted in accordance burner, however, is operated with gas supplied stream may be controlled by a diaphragm-operated valve, the diaphragm being subjected on one side to the high pressure-in the main and on with the new demand of the burner. If desired,

the supply of gas to the main burner may be controlled thermostatically in accordance with the invention by thermostatically valving the flow of gas in the small stream between thelow pressure zone and the heater.

A pressure regulator made in accordance with the invention comprises a housing having inlet andputlet openings and a valve seat between the openings. Above the seat and coacting therewith is a valve member mounted on a diaphragm which is likewise positioned above the seat. The diaphragm is subjected on its lower face to the inlet pressure and on its upper face to the pressure in an intermediate-pressure chamber, the latter being supplied with gas through a bleed passage leading from the inlet side of the valve seat. Above the intermediate-pressure chamber and separated therefrom by a partition is a.

low pressure chamber supplied with gas from the intermediate chamber through a small duct in the partition. The passage of gas between these two chambers is regulated by a .small auxiliary valve controlled by an auxiliary diaphragm forming 'one wall of the low pressure chamber. Preferably. the auxiliary valve is formed with a head in the intermediate chamber and has a stem extending loosely through the duct, the auxiliary diaphragm being movable relative to the stem and adapted to engage the same and open the auxiliary valve. The stem may be held in the duct by a spring secured tothe partition in the intermediate chamber and engaging the head oi. the valve so as to urge the head against the partition and close the duct. Suitable means are provided for connecting the low pressure chamber to the outlet side of the main valve.

The new regulator operates to maintain at all times a substantially constant pressure in the outlet side of the main valve and in the low pressure chamber. It the outlet pressure becomes too low, the resulting decrease in pressure in the low pressure chamber causes the auxiliary diaphragm to move into contact with the stem of the auxiliary valve and open the latter against the action of the spring acting on it. The gas in the intermediate chamber may then pass at a greater rate to the low pressure chamber, whereby the pressure in the intermediate chamber is reduced and permits the inlet pressure acting on the bottom of the main diaphragm to move the main valve away from its seat. If the outlet pressure should become too great, it acts through the low pressure chamber to move the auxiliary diaphragm away from the auxiliary valve. The spring then shuts down the auxiliary valve so as to decrease the flow from the intermediate chamher to the low pressure chamber.

As a result, the pressure in the intermediate chamber builds up and acts on the top of the main diaphragm.

to force the main valve toward its seat. It will be apparent that the main valve more or less floats with its diaphragm, since the total inlet pressure acting on the bottom of the diaphragm substantially balances the weight of the valve and the total intermediate pressure acting on the top of the diaphragm. Accordingly, there is practically no stress exerted on the diaphragm.

. gas to operate the pilot, regardless of changes in operating conditions, and the movements of the auxiliary valve incident to changes in operating conditions results automatically in adjustment of the main valve to compensate for these changes.

For a better understanding of the invention reference may be had to the accompanying drawings, in which:

Fig. 1 is a plan view of one form of the new regulator with the cover and the auxiliary diaphragm removed;

- Fig. 2 is a longitudinal section on the line 2-2 in F 1:

Fig, 3 is a section on the line 3-3 in Fig. 1;

Fig. 4 is a section on the line 4-4 in Fig. 1, the lower part of the section, however, being in the plane of the lower part of the line 4-4 in Fig. 1, as indicated in Fig. 2;

Fig. 5 is a longitudinal section showing one application of the new regulator, the regulator being illustrated somewhat diagrammatically;

Fig. 6 is a view similar to Fig. 5 showing a modified form of the regulator in whichthe flow of gasfrom the low pressure chamber to the outlet side is controlled thermostatically, and

Fig; 7 is a view similar to Figs. 5 and 6 showing another modification of the regulator in which the flow of gas from the low pressure chamber to the outlet side is controlled by the temperature of a pilot.

In the drawings, the numeral l0 designates a housing comprising a hollow section II of generally cylindrical form and provided at its ends with hollow bosses forming inlet and outlet openings I2 and I3, respectively. At the top, the section H is provided with an opening il' partly forming a circular valve seat I! disposed slightly ,below the top of the section I l.

One of the flanges I4 is connected to the cylindrical body of the section II by a pair of heavy fillets l8 and I9. The fillet I8 is drilled to form a bore 20 leading obliquely upwardly from theinlet side of the partition IS, the outer end of the bore being closed by a plug 2|. A vertical I bore 22 is drilled in the flange l4 and connects with the oblique bore 20 near the plug. Similarly, a bore 23 in the flllet l9 leads to the outlet side of the partition l5 and is closed at its outer end by a plug 24, and a vertical bore 25 in the flange connects with the bore 23.

Mounted on the main section II is a relatively thin intermediate section 21 provided with a horizontal partition 28, the section being formed with recesses above and below the partition. The side edges of the intermediate section are straight dish-shaped member 3| is centrally disposed on the upper face of the diaphragm, and on the lower face directly over the valve seat 19 is a metal disc 32, the disc and the member 3| being secured to the diaphragm by a stud on the disc extending up through the diaphragm and the dish-shaped member and upset at its end against the latter. A thin rubber-like disc 33 is cemented or otherwise secured to the metal disc 32 and forms a valve member ooacting with the seat ll.

The section 21 is formed near one corner with a vertical bore 35 aligned with the bore 22 in section II, and the bore 35 communicates with the chamber at through email bleed passage 38. A similar bore 35' is formed near the opposite corner of the section 21, the latter bore being so positioned that it overlies the bore 22 from the chamber 38 into a chamber 38 between the top of the partition and a diaphragm 38. The passage of fluid between the two chambers is controlled by an auxiliary valve 48 adapted to seat against an offset portion on the bottom of the partition 28 and formed with a stem 48' which extends loosely through the duct 31. The valve member 48 is normally held against its seat by means of a leaf spring including a hub 42 through which a projection on the valve member extends, the spring alsoincluding arms 43 extending radially outwardly in zigzag fashion to a rim 44 which is secured to the lower face of. the partition by rivets 45. A passage 41 leads outwardly from chamber 38 to a vertical bore 48 aligned with an opening in the lower diaphragm and the bore 25. A vertical bore .48 similar'to bore 48 is formed in section 21 near the opposite corner and is connected to the chamber 38 through a passage 41'. The bore 48 is adapted to align with the bore 25 when the upper section 51, the three housing sections being secured together by'screws 52 extending loosely through the sections 5| and 21 and threaded into the main section. A coil spring 53'is engaged at its lower end with the dishshaped member 58 and is held at its upper end in an inverted dish-shaped member 53' which is suspended on the lower end of an adjustment screw 54 threaded through the top of the housing.

While the new regulator may be used for various purposes, I have illustrated in Fig. 5 one use of the regulator in which it controls the flow of gas to a pilot and a burner. As there shown, a pipe 58 leading from a gas supply main is threaded into the inlet opening l2 of the housing, and a pipe 51 threaded into the outlet opening l3 leads to a burner (not shown). Between the burner and the housing is a fitting 58 having a nipple 58 threaded into the pipe 51. The fltting is adapted to supply gas to a pilot tube 88 located sufficiently close to the burner to ignite the gas flowing through it. The flow. of gas to the pilot tube may be regulated manually by means of a needle valve 8| threaded into the erted by spring 53 against the diaphragm 38 is adjusted so that the latter engages the stem 48' andnormally holds the auxiliary valve 48 in a throttling position to pass just enough gas to operate the pilot 88. The pilot is then continuously supplied with gas from the main 58 through inlet opening l2, passages 28, 22, 35 and 38, chamber 38, duct 31, chamber 38, passages 41,- 48, 25 and 23; outlet openingl3 and pipe- 51. This stream of gas is relatively minute because of the small size of the bleed passage 38 and the slight displacement of auxiliary valve from its seat but is suilicient to operate the pilot safely when the main valve 33 is closed. The diaphragm 38 controls the auxiliary valve so as to maintain a substantially constant low pressure in chamber 38 for operating the pilot, regardless of changes in operating conditions. That is, if thepressure in the-chamber 38 tends to decrease for any reason, the diaphragm 38 moves the auxiliary valve further from its seat and allows more gas to pass into the low pressure chamber 38 from the intermediate chamber 38. Conversely, if the pressure in chamber 38 becomes too great, the diaphragm 38 is moved upwardly and permits spring 41 to move the auxiliary valve toward its seat and cut down the flow of gas to the low pressure chamber from the intermediate chamber 38.

The auxiliary valve 48 not only maintains the required minimum flow for the pilot but also controls the main valve 33. That is, when the burner.

is turned off, the auxiliary valve is normally held by diaphragm 38 in its throttling position in which it passes just enough gas to the chamber 38 to operate the pilot. In this position of the auxiliary valve, the pressure in the intermediate chamber 38 is relatively high, since the rate of flow from the intermediate chamber through the duct 31-ismomentarily relatively low as compared with the rate of flow from the inlet through the bleed passage 38 so that the pressure in the intermediate chamber may build up to nearly equal the inlet pressure. Consequently, the total pressure exerted by the fluid in chamber 38 on the diaphragm 28, together with the weight 01' the parts mounted on the diaphragm, is suflicient to seat the valve 33 against the total inlet pressure exerted on the bottom of diaphragm 28. However, when the bumer is turned on, there is a tendency to decrease the pressure in pipe 51 and low pressure chamber 38, whereby the diaphragm 38 moves downwardly and forces the auxiliary valvefurther from its seat so that a greater amount of gas may pass from the intermediate chamber 38 to the chamber 38. This increased flow not only tends to counteract directly the drop in pressure in the pipe 51 but also decreases the pressure in intermediate chamber 38 relative to the inlet pressure in pipe 58, and as a result the latter pressure acting on the bottom of diaphragm 28 is suflicient to raise valve 33 against the decreased pressure in chamber 38. Gas then passes through the seat I1 and outlet opening I 3 so as to supply the burner and maintain ,the required gas pressure in pipe 51. During the operation of the burner, any change in the demand of gas consumed by it is reflected in a change in pressure in the pipe 51 and the low pressure chamber 38, and this pressure change moves the diaphragm 38 and auxiliary valve 48 so as to change the pressure in intermediate chamber 38 and thereby readjust the position of the main valve to meet the new demand.

Because of the small size of auxiliary valve 48, it is possible to maintain a delicate pressure control of an extremely small flow .iust suflicient to operate the pilot. The spring 4| in conjunction with the diaphragm 38 provides a delicate balance for the auxiliary valve which results in an extremely sensitive operation, whereby the auxiliary sure in the chamber 38. Since the difference in pressure in chamber 38 and section is relatively small and the auxiliary valve 48 with its delicate spring loading exercises only a slight pressure on the diaphragm, the latter is not subjected to any substantial stress. Also, the main diaphragm 29 is stressed only slightly, because the total inlet pressure actingon the bottom of the diaphragm is substantially balanced by the weight of the parts on the diaphragm and the total, pressure in the intermediate chamber acting on the top of the diaphragm. Accordingly, the diaphragms may be used for long periods of time without replacement. By making the diaphragm 39 of thin metal, such as aluminum, any tendency for the diaphragm and the auxiliary valve to flutter is reduced.

The regulator may be readily disassembled by removing the screws 52 and is easy to assemble because the spring 53 and the member 53' are secured to section 5| by the adjustment screw, and the valve 48 and leaf spring 42 are secured to the intermediate section at all times. In assembling the regulator, the intermediate section 21 may be mounted on the lower section in any position so long as the straight sides of the intermediate section coincide with the straight sides of flanges M. This is'so because of the bores 35' and 38 and their connecting passages formed in the side of the intermediate section opposite the bores 35 and 38. The new regulator may be made of extremely small size for a given capacity, since the small auxiliary valve 40 permits the use of a correspondingly small diaphragm to actuate it.

By making the top section 5| relatively large, it is unnecessary to provide a vent between the interior of the section and the outside of the housing, because the pressure of a large volume of air trapped in the section 5| does not change substantially with the slight movements of diaphragm 38. By thus eliminating the usual air vent, it is'impossible for gas to escape from the inlet I2 through the housing in the event that either or both or the diaphragms should rupture. Accordingly, it is unnecessary to connect the atmospheric chamber at the top of the housing to a flue as is common in devices of this type.

If desired, the flow of gas through the main valve 33 may be controlled thermostatically by a slight modification of the regulator, shown in Fig. 6. As there shown, the outlet passage 48 in the intermediate section is eliminated and the low pressure chamber 38 is connected by a small pipe 83 to a casing 64, where the stream of gas flowing from chamber 38 divides. One branch of the stream passes through a small opening 85 to a pipe 66 communicating with the pipe 51, the flow of gas through the opening 65 being adjustable manually by a needle valve 81 threaded into the casing. The other branch of the stream flows through a valve seat 68-to the pipe 86, and the passage of gas through the seat 68 is controlled by a thermostatic valve 68 responsive to the temperature in an oven, or the like.

With this construction, a continuous stream of gas is supplied from the low pressure chamber 38 through pipe 63, opening 65 and pipes 66 and 51 so as to maintain a safe minimum flame at the burner. A slight additional amount may also be supplied through the seat 68 depending on the position of thermostatic valve 69. The operation of the regulator is similar to that of the regulator shown in Fig. 5, except that when the valve 63 moves toward its seat, the flow through pipe 63 is decreased, whereby the pressure in chamber 38 builds up. This causes the diaphragm 39 to move upwardly and allow valve 48 to cut down the flow of gas from the intermediate chamber -30 to chamber 38. As a result, the pressure in chamber 38 builds up and moves the main valve 33 toward its seat so as to cut down the supply of gas to the burner. However, when the thermostat moves valve 69 away from its seat, the gas flows through pipe 63 at a greater rate and causes a decrease in pressure in chamber 38. The diaphragm 39 then moves valve away from its seat and allows gas to flow through duct 31 at a greater rate, whereby the pressure -in chamber 38 decreases and allows the main valve to move away from its seat.

In the modification shown in Fig. 7, the outlet from the low pressure chamber 38 is in the form of a pipe H leading to acasing 12, where the gas from chamber 38 passes through a valve seat 13 to a pilot 14. The rate. of flow of gas to the pilot may be controlled by a needle valve' 15 threaded into the casing. The interior of the casing communicates through a pipe 16 to the' pipe 51 which leads to a burner (not shown) adapted to be lighted by the pilot. The passage of gas through valve seat 13 is controlled by a valve member T1 operated by a bimetallicv thermostat 18. A metal bracket I9 engages one end of the thermostat l8 and has a portion disposed near the flame of the pilot, the bracket 19 and thermostat 18 being secured to the casing by a screw 80.

When the pilot 14 is burning, the heat from the flame is conducted through the bracket 19 to thermostat l8 and causes the latter to assume the position shown in Fig. '7, wherein the valve 11 is held away from its seat. Gas may then flow from low pressure chamber 38 through pipe 1| and valve seat 13 to the pilot. The operation of theregulator is similar to that of the .regulator shown in Fig. 5, except that if the pilot 14 is accidentally extinguished, the thermostat l8 cools and moves valve 11 against its seat. This cuts 01f the supply of gas to the pilot and causes the pressure in chamber 38 to build up until the diaphragm 39 allows the auxiliary valve to close. As a result, the pressure builds up in intermediate chamber 38 and acts on diaphragm 29 to seat the main valve '33. Thus, the regulator controls both the pilot and the burner and acts positively to cut off the flow of gas to these parts when the pilot flame is extinguished. When the pilot is extinguished and the valve 11 closed, the pilot may be ignited by holding a match near the thermostat 18 until the latter opens the valve 11 and then applying the match to the pilot.

It will be observed that with the construction shown in Fig. 6, the gas passing through pipe 83 to the valve 69 is maintained at a constant pressure regardless of pressure variations of the gas in the inlet pipe 56. Accordingly, the thermostat may be accurately calibrated to respond to temperature changes and throttle the flow of gas in the main stream in accordance with the demands of the thermostat. Likewise, in the construction shown in Fig. "I, the gas passing through pipe H is maintained at a constant pressure,

compact form as compared with those of prior constructions. The regulators now on the market for use on domestic appliances are at least 4 inches in diameter, because the conventional regulator requires a long stroke for the valve which, in turn, requires-the use ofa large flexible diaphragm and along spring to control the diaphragm through the long stroke of the valve.

The regulator of the invention is made relatively small by providing two diaphragm's, one operating as a pressure regulator for a very small quantity of gas which controls the other diaphragm, thelatter serving to amplify the movements of the pressure regulator so as to operate a large gas valve. Thus, the diaphragm associated with the small pressure regulator operates with a short stroke so that it may be made of a small diameter and relatively still, and the spring controlling the diaphragm may be relatively short, as it flexes very little in operation. The other diaphragm does not require a spring and is subjected to almost equal gas pressures on both sides, so that it may be made of very flexible material to provide the longer stroke required. This flexible material would be unsuitable in a conventional pressure regulator where the diaphragm is subjected to the outlet gas pressure on one side and atmosphere on the other with consequent danger of rupture, but is entirely satisfactory in the new regulator where it floats under negligible strain between almostequal gas pressures on opposite sides.

Proper regulation of the flow of gas in both very small and large volumes has been difllcult to obtain heretofore in a single valve. The conventional pressure regulator is a compromise between these two extremes, but a gas range or a water heater requires close regulation for a constantly burning pilot using less than half a cubic foot of gas an hour and for intermittently operating burners using as much as 200 cu. it. an hour. In the new regulator, these requirements are met by providing two valves, one large and one small, the small valve supplying the pilot and the large valve handling the requirements of the burners. The area of the regulating valve 40 is so small in comparison to the area of the diaphragm actuating it that its reaction on the diaphragm is substantially negligible. In the con-' ventional pressure regulator, on the other hand, the large valve is subjected to the widely varying inlet pressure on one side and to a constant outlet pressure on the other side 'and exerts a varying reaction on the diaphragm.

One of the principal objections toprior pressure regulators for demestic appliances is the necessity of venting the regulators so as to prevent the escape of gas into the room in the event of leakage through the diaphragm. Various expedients have been devised to overcome this difficulty, such as a floating piston valve or a valve operated by an auxiliary diaphragm to close a vent to the atmosphere in case of rupture or leakage of the main diaphragm, but these expe dients have not proved entirely satisfactory. In the regulator of my invention, the useof such expedients is unnecessary, because the auxiliary diaphragm 39 has a small diameter and is relatively still so that it does not appreciably compress the air in the chamber above it. During operation, the diaphragm 39 moves only about inch so that the air displaced by it is 1 100 of an negligible, and no vent need be provided to atmosphere. This eliminates the usual safety device or extra flue pipe.

I claim: v 1. A thermostatic pressure regulator comprising a housing having inlet and outlet openings, 8.

main valve controlling flow through the housing between the openings, pressure-responsive means in the housing for actuating the valve and forming one wall of a chamber in the housing, the housing having. a constant bie 'zl passage therein leading from the inlet side oi the main valve to said chamber, a second pressure-respon-- sive means in the housing forming one ,wall of a second chamber, a duct connecting said chambers for bleeding fluid from the first chamber into the second chamber, an auxiliary valve for regulating flow through the duct and controlled by the second pressure-responsive means, means connecting said second chamber to the outlet side of the main valve, and thermo-responsive means for valving the flow of fluid through said connecting means.

2. In a device for supplying gas toa main burner and a pilot for the burner, the combination of a housing having an inlet for connection to a source of gas supply andan outlet for connection to the burner, a main valve controlling flow between the inlet and outlet, pressure-responsive means in the housing for actuating the valve and forming one wall of a chamber in the housing, the housing having a constant bleed passage therein leading from the inlet side of the main valve to said chamber, a second pressure-responsive means in the housing forming one wall of a second chamber, a duct connecting said chambers for bleeding fluid from the first chamber into the second chamber, an auxiliary valve for regulating flow through the duct and controlled by the second pressure-responsive means, means for connecting the second chamher to the pilot and for connecting the pilot to the burner at the outlet side of the main valve, and thermo-responsive means subjected to heat from the pilot light for valving the flow through said connecting means.

3. In a pressure regulator, a primary valve having an inlet and an outlet, pressure-responsive means for operating the valve and partly defining a chamber, means for bleeding fluid from the high pressure side of the valve to the chamber, aduct between the chamber and the outlet side of the valve, a secondary valve in the duct responsive to pressure at the outlet side of the primary valve for controlling flow through said duct, and thermo-responsive valve means in said duct between the secondary valve and the outlet side of the primary valve for controlling flow through the duct.

4. In a pressure regulator, a primary valve having an inlet and an outlet, pressure-responsive means for operating the valve and partly defining a chamber, means for bleeding fluid from the high pressure side of the valve to the chamber, a duct between the chamber and the outlet side of the valve, a secondary valvein the duct responsive to pressureat the outlet side of the primary valve for controlling flow through said duct, a pilot burner connected to the outlet side of the primary valve, and valve means in said duct between the secondary valve and the outlet side of the primary valve and responsive to heat from the pilot burner for controlling flow through the duct.

BENSON F. WADDELL. 

